AIR COOLED CONDENSER INSTALLATION/OPERATION & MAINTENANCE MANUAL © ACC-2 Thru ACC-37 @ COMPU-AIRE, INC. 8167 Byron Road, Whittier, Ca 90606 Phone: (562) 945-8971 Fax: (562) 696-0724 Website; wuw.compucaire.com E-mail: cs@compu-airel.com ISO 9002 Registered CompanyINDEX DESCRIPTION PAGE 1, GENERAL SAFETY INFORMATION 1 2. INSPECTION 1 3. RIGGING AND HANDLING 7 4, LOCATING THE CONDENSER 3 5. DIMENSIONL DATA 4 6. ELCTRICAL DATA 7 7. REFRIGERANT PIPING AND REFRIGERANT CHARGE 8 8. FIELD WIRING 9 9. WIRING DIAGRAMS, IL 10. START UP 14 11. LOW AMBIENT CONTROL OPTIONS 15 12. MAINTENANCE 19 13. SPARE PARTS LIST 20 14. PIPE SIZES 21 15. WARRANTY 22GENERAL SAFETY INFORMATION 1. Installation and maintenance are to be performed by qualified personnel only. Assure all field wiring conforms to the requirements of the equipment and all applicable national and local codes. Assure the voltage on the unit nameplate agrees with the power supply available, Avoid contact with any sharp edges and coil fins. It may cause serious injury, 4, Make all power sources are disconnected before any service work is performed on the equipment. INSPECTION 1, Check all items against the bill of lading to make sure all crates and cartons have been received. 2. Inspect all items for either vis le or concealed damage. If there is any damage, REPORT TO THE CARRIER. Comp , Inc. IS NOT RESPONSIBLE FOR FILING OF ANY CLAIMS. ALL NEEDED INSPECTION AND CLAIM FILING IS THE RESPONSIBILITY OF THE RECEIVERRIGGING AND HANDLING Move the unit near to the installation location using a crane or forklift before uncrating to prevent damage in transit Fach fan section has heavy leg supports with lifting holes at the top. Do not lift with a choke sling around the unit. Spreader bars are recommended for lifting multiple fan units. Under no circumstances should the coil headers or piping be used for moving or lifting the condenser. Leg assembly: The legs must be unbolted from the shipping position and extended prior to placing the unit on its pad. Each leg extends down approximately 18 inches and reattaches using same bolts. Conese BPMN Taos tee een 2. SOMO RE rom ya" guts AT Hod eA Leo SRSA HS hoe Gow oF REATAGND wok HE TOUR eckTs Ve ge srsLOCATING THE CONDENSER The remote heat exchangers must be located in an area that will ensure maximum security; maintenance accessibility and free air flow into and out of the unit, ‘The unit should not be placed closer than 48 inches from any wall or other obstruction. When two or more units are installed in the same area, space them apart by a minimum of 48 inches. Short-circuiting of the airflow or the intake of warmer air from another unit will seriously degrade the performance of the air-cooled condenser. Structural supports and roof or platforms should be sufficiently strong to support the condensers operating weight. For roof installations, mount the condensers on steel supports in accordance with local codes. For ground installations, a conerete pad is sufficient to carry the load, Noise consideration should also be considered when locating an air-cooled condenser. Proximity to windows, walls, and surrounding structures can cause objections by the occupants. MINIMUM CLEARANCE PLAN VIEWT00-006-2E9, "pon )*| wasaaNo9 4771009 uI¥ sour*zuly—NdNOo | IOAVHOSIA TWOLLAIA NOL7T2 G'TIOV _— MOTI uv | 41ITINO wk LIN J | SSS = xo Lonuart Vier. ‘wont VILVd TVOISXHd Ta Guprap-toe-ae9 wa Gor W/kart sreanduosT ZT ————T z + 5 — — (200-006-022, mal "| saSNIGNOD Ga1009 WIV “oultzulV-NdNOO 87 NUHL § -DIV TInaAO : —— (wnuogez) .¢¢e ———____—-+ ag 92-12 20¥ e (umtiggzz) .06 fg “Tivagao |-——— (unt) 7 eae}! 90 = |-———— (unapast) 09 —| rrvaao ; Tvaano e— (aru TzT),8F \|z (arwigte) ze 6-5 26v (aan) saion onunoon | (aun) | | (kt) SaT0H ||-—(wurz92) 06 | (araige),2/T T (wmeyt1),Sh | [8/8 1/18 NUINNOM “Via A ——— : (aug t),.8/¢ (uxmge) | ' E z Sales (wIUIFEy) . Go 9/2 ore és LaTLAO EC case r ‘umug901) Fo tha Ge? 4 (aa) “via (amest).9 | IS 4aaoo (wuige) 2/1 1 £08 Naa NUALaa SWIOH ONILATT “TOULNOD" [S20-006-02Z, YISNIGNOI ATTOO) AI¥ ‘oul'FulV—NdWNOO ly OF 8 LE ‘0f-DOV (arg tzT), fl E (arasote) seeeT “ns WASTART-UP Prior to star-up check the following items: 1. Check fans for freedom of movement. Check all fan blade set screws, motor mounts, and mounting leg fasteners. 3. Check all electrical connections for tightness, 4. Check that the nameplate voltage matches the power supply voltage. Upon start-up check the rotation of all fans to insure that air is being discharged up out of the fan discharges. 14LOW AMBIENT CONTROL OPTIONS: A) FAN SPEED CONTROL (Low ambient control up to -20° F) The Fan speed control provides an infinite number of speed variation(s) on specially designed permanent split-capacitor motor(s). Controller varies the quantity of air passing through the air- cooled condenser by directly sensing the refrigerant pressure, Fan speed control provides air delivery in direct proportion to heat rejection requirements of the system, This is to maintain optimum system capacities and pressures in widely varying operating ambient(s). As ambient temperature drops, the refrigerant pressure will also drop. As the ref. pressure drops, this will be sensed by the pressure transducer and the air quantity will be reduced by reducing the motor (fan) speed. Fan Speed Controller Refrigerant Connection: The fan speed control requires that the capillary be connected to the hot gas header through the shraeder fitting provided. Also, for multi-fan unit(s) there are thermostats for each condenser fan motor with the exception of the control motor (variable-speed). The thermostats should be set in accordance with wiring diagram provided with the unit. Note: Fans are numbered starting at the header end of the condenser. Adapter Fitting P66BAB Fan Speed Control with DepressorB) HEAD PRESSURE CONTROL VALVE (Low ambient control below -20° F) This type of low ambient control includes head pressure control valve(s) and the receiver(s) package. The receiver(s) are installed in separate enclosure(s). The enclosure(s) are shipped loose for field installation at the condenser. The head pressure control valve(s) are installed on the condenser or shipped separately for field installation on the air-cooled condenser. Upon receipt of these items should be checked against the packing list and stored inside the building until they are ready to be installed. Operation: During periods of low ambient temperatures the condensing temperature falls until it approaches the setting of the head pressure control valve, which throttles towards a closed setting, thus restricting the flow of the liquid from the condenser. This causes the refrigerant to back up in the condenser and reduces the effective condenser surface. The check valve opens after the head pressure control has offered enough restriction and then causes the differential between the condensing pressure and the receiver pressure to exceed 20 psig. The hot gas flowing through the check valve serves to heat the cold liquid being passed by the limitizer valve. Thus, the liquid reaches the receiver warm and with sufficient pressure to assure proper expansion valve operation. The check valve and limitizer valve modulate the flow automatically to maintain proper condensing pressures. Discharge Head Pressure Control Valve OROA Installation of Head Pressure Control Valve: There is one head pressure control valve on each of the limitizer system. These control valves, or limitizer valves as they are called, can be installed in a horizontal of a vertical line, whichever application permits easy adjustment and accessibility to either valve. Care should be taken to install the valves with the flow in the proper direction. It is 16important that head pressure control valve be protected by wrapping the valve with a wet cloth to Keep the body of valve at a temperature below 250° F. It is important to keep the flame away from e-r—_~-——s— __ C_————- Subjected to pressure in excess of 250 psig during the leak testing procedure. The limitiver valves are factory set to maintain 180 psig, The Head Pressure Control Valves are hermetically sealed therefore, when a valve comes inoperative, it must be replaced. There are two types of ‘malfunctions that may occur. (I) Failure to open or (II) failure to close {particles of solder are in the system, they can restrict the orifice of the valve and cause the valve fo malfunction. If this occurs, gently tap the valve, this will possibly allow the particles to flow through the valve. Since a synthetic material is used in the construction of the valve, damage to this will cause hot gas to leak constantly. If this occurs, the valve must be replaced Liquid Receiver(s) Installation: Liquid receiver(s) are factory installed in the separate enclosure(s). These enclosure(s) need to be field installed on side(s) of the air-cooled condones Also, ihe liquid receiver(s) need to be field piped. Install a Refrigerant Sight Glass (By Others) immediately after the Liquid Receiver Outlet. Only the sight glass at the receiver outlet should be used to determine if the additional refrigerant must be added. Liquid Receiver(s) are wrapped with the Self Regulating Heating Cable and insulated. Provide 240Vac Power Supply to the Heating Cable as shown in the wiring diagram. 17wan Asyovela LuOdans: a 7 oN 4waAo9 aAONSY (dA L108 4 x aie (aw og zn x ons (8 aAD wansvm ~ ‘ONRIAS OWS 3dIs 3LISOddO WOIdAL = 7 SUNSOTONA WBAIZOIS | ‘WASNIGNOD GI1000 UNV. (dA) waHsyM MOOT ONTES 911MAINTENANCE Maintenance of the air-cooled condenser is extremely important for extended life and peak performance. Following scheduled maintenance is recommended. The frequency of the maintenance plan may vary based on site condition, The Warranty does not cover corrosion, misuse, or misapplication of the condenser. 1. Shut all power off to the air cooled condenser and the entire system at the closest disconnect switch and use a lock to prevent others from turing power back on to the unit. 2. Remove Fan Guards. Remove all large debris (leaves, paper, cardboard, plastic film, etc.) from the top as well as beneath the unit. Keep the area clean around the condenser by removing loose debris around the air-cooled condenser. 4. Inspect the unit for damaged fins caused by the debris. Comb out any bent fins with a fin comb. Inspect the unit for signs of corrosion. Note the area and amount of corrosion in your maintenance reports. 5. If the heat transfer surface require cleaning use the following procedure. Use a cleaning solution that is compatible with the finned material and any protective coating that may have been applied to the heat transfer surface, Follow the cleaning instructions exactly as described by the manufacturer of the cleaning agent. It is extremely important that a proper rinse be applied to the core once the cleaning process is completed. Use a hose with a spray wand and rinse from the top of the unit only. Do not rinse from the underside, as this will not properly flush the cleaning agent from the core. Any residue of cleaner left for any extended period begin to corrode the heat transfer surface. It is recommended to use a detergent type cleaner like Cal-Clean as a cleaning solution. 6. Inspect all fan and motor fasteners for tightness before installing the fan guards. 7. Turn power back on to the system. For inland installations (30 +(plus) miles from any body of salt water): Schedule visual inspection of the heat transfer surface and unit once every 6 months, Clean the heat transfer surface should it show signs of significant dirt accumulation. Recommended minimum cleaning cycle is once every 12 months. For seacoast installations (Up to 30 miles from any body of salt water): Schedule visual spections of the heat transfer surface and unit once every 3 months. Clean the heat transfer surface thoroughly every 3 to 6 months with water to remove accumulated layers of salt. Every 12 months clean the heat transfer surface with an approved cleaning solution. 19SPARE PARTS LI AIR COOLED CONDENSER - ACC(s) PART NUMBER DESCRIPTION REFRIGERATION COMPONENTS 255-200-022 A/C LIMIT CONTROL: 100-425 PSI 255-201-012 LIMIT CONTROL COVER AIR MOVING PARTS 209-420-003 PROPELLER FAN, 4 BLADE, 20" DIA 209-424-003 PROPELLER FAN, 4 BLADE, 24” DIA 213-002-002 HEX HUB FOR COND. FAN 1/2” BORE. 206-005-012 MOTOR 1/2 HP, 208/1 ELECTRICAL COMPONENTS 275-640-021 TRANSFORMER 40VA-24V, PV: 208/220 275-040-023 TRANSFORMER 40VA-24V, PV: 460 275-675-012 TRANSFORMER 75VA-24V, PV: 208/460 274-020-212 CONTACTOR 2 POLE/20 AMPS OPTIONAL PARTS (IF USED) 206-007-013 VARI-SPEED MOTOR, 3/4 HP, 208V/1 206-007-014 VARI-SPEED MOTOR, 3/4 HP, 460V/1 278-370-010 CAPACITOR 10MFD @370 Vac CAPACITOR 12.5MFD @370 Vac 256-016-031 FAN SPEED CONTROLLER-1 SENSOR, 60Hz 256-026-141 FAN SPEED CONTROLLER-2 SENSOR, 60Hz 242-001-001 HEAD PRESS. CONTROL VALVE ~7/8” UNIT MODEL(s) __(Where used) ACC-2,3 ACC-6 & UP ACC-2, 3 ACC-2 THRU 9 *) ACC-2 THRU 9 ACC-2 THRU 9 ALL ACC(s) ALL ACC(s) ALL ACC(s) ALL ACC(s) ALL ACC(s) ALL ACC(s) ALL ACC(s) ALL ACC(s)COMPU-AIRE, INC. 8167 Byron Rd., Whittier, CA 90606 PH: (562) 945-8971 FAX: (562) 696-0724 SUGGESTED REFRIGERANT PIPE SIZES "QUICK RULE OF THUMB" TONS [DISTANCE BETWEEN INDOOR UNIT AND AIR COOLED CONDENSER 25" 50" ae 100° Hig. | Dis. | iQ. | Dis. [iQ | pis. [tiQ. | Dis. LINE LINE [LINE | LINE [LINE | LINE LINE LINE 2 qe" |" | sie" | 12" | sie" ee 3 se" | 4" | 3a" | 1" | aan 42" | sia" 4 3/4" sia" | 7a" | 58" | 7/8" 7/8" 5 78" | 5/8" 518" | 7/8" 1118" 712 5/8" 78" 3/4" 3/4" 11/8" 11/8" 10 5/8" | 11/8" 3/4" 3/4" 11/8" 1 3/8" 1214/2 3/4" | 11/8" 78" 7/8" 13/8" 13/8" 15 3/4" | 11/8" 7/3" 7/8" 13/8" 15/8" NOTES: 1. Distances shown are one way. Pipe sizes are based on Total Equivalent Length (TEL). Verify sizes with ASHRAE Standards. 2. Compu-Aire will not be responsible for any errors in pipe sizing or improper running of the piping. It is highly recommended that sound engineering practices be used for routing, piping, "p" traps, double risers and insulator requirements. 3. LIQ. = LIQUID DIS. = DISCHARGE 4. All sizes are copper O.D. 5. Provide isolation valves for piping lines outside any air conditioner unit. 21WARRANTY Refer to the Compu-Aire, Inc. Sample Warranty Certificate below for warranty details. ag ES ae u 7 z a ve By ge a3 Ss a8 ae 5a #8 £= aE Be gs ES 23 g o Z| so that the unit warranty can be made effective. Failure to do so will void the unit warranty. 13 pass $1509) YGHLO YO AOAVT AaNIONT LON SOM KENVAEVA SEL a em 8 signe sues 8 TON PR 2 bo tos ary nant m esas pmo ace AINVIRIVAN AVA JNO MAVANVIS ATdWVS 22